Lightweight, high flow hose assembly and method of manufacture

ABSTRACT

A hose assembly, preferably a garden hose assembly, including a jacketed tube that is lightweight, durable and versatile. The tube is able to expand longitudinally along the length-wise axis of the hose between hose ends, as well as radially or circumferentially, to an expanded state in response to application of at least a minimum fluid pressure to an inner tube of the hose. Once the fluid pressure falls below the minimum fluid pressure, the hose assembly will contract. The two layer construction of the hose assembly allows for storage in relatively compact spaces, similar flow rates, approximately one-half the weight, and improved maneuverability when compared to conventional hose constructions. In one embodiment the jacket is formed around the tube in a continuous process that welds a material, preferably using hot air, into the jacket. The welded joint forms a region of jacket that is preferably about twice the thickness of the rest of the jacket. This thicker region results in a stiffer section of jacket that makes the hose more controllable and consistent in use.

FIELD OF THE INVENTION

The present invention relates to a hose assembly, preferably a gardenhose assembly, including a fabric and/or non-fabric jacketed tube, thatis lightweight, durable and versatile. The tube is able to expandlongitudinally along the length-wise axis of the hose between hose ends,as well as radially or circumferentially, to an expanded state inresponse to application of at least a minimum fluid pressure to an innertube of the hose. Once the fluid pressure falls below the minimum fluidpressure, the hose assembly will contract. The two layer construction ofthe hose assembly allows for storage in relatively compact spaces,similar flow rates, approximately one-half the weight, and improvedmaneuverability when compared to conventional hose constructions. In oneembodiment, the jacket is formed around the tube in a continuous processthat welds a fabric and/or non-fabric, preferably using hot air, intothe jacket. The welded joint forms a region of jacket that is preferablyabout twice the thickness of the rest of the jacket. This thicker regionresults in a stiffer section of jacket that makes the hose morecontrollable and consistent in use.

BACKGROUND OF THE INVENTION

Numerous different types or styles of garden hoses are known in the artand commercially available.

For example, traditionally conventional hoses are polymeric and can bereinforced, have a substantially fixed longitudinal length, and haverelatively low radial expansion upon internal application of fluidpressure. Due to their construction, some conventional hoses can berelatively heavy and cumbersome to use and store.

More recently, garden hoses longitudinally expandable along their lengthmultiple times as compared to the length of the hose in an unpressurizedor contracted state have been introduced. In some embodiments such hoseshave a construction that includes a jacket that surrounds an expandablefluid conveying tube. Longitudinally and radially expandable hoses arepopular for a variety of reasons including, but not limited to,lightweight construction and ease of storage when not in use.

Longitudinally expandable hoses are commercially available from a numberof sources. The hoses are also described in various patents andpublications, see for example: U.S. Pat. Nos. 6,948,527; 7,549,448;8,371,143; 8,776,836; 8,291,942; 8,479,776; 8,757,213; as well as U.S.Patent Application Publication Nos. 2014/0150889; and 2014/0130930.

A problem with some of the length expandable hoses is that they cankink, bulge, fail and/or exhibit leakage, at one or more points alongtheir length, for example at a connection point to a coupler or fittingat the end of the hose, after a number of expansion and contractioncycles.

SUMMARY OF THE INVENTION

The problems described above and others are solved by the hoseassemblies of the present invention which are relatively lightweight, ascompared to the traditionally conventional hoses, durable, andversatile. In some embodiments, the hose assemblies provide a flow ratesimilar to a conventional garden hose at approximately one-half theweight. The hose assemblies also provide improved maneuverability due totheir light weight, kink resistance in view of the non-bonded, two-layerjacket construction and ease of storage over a conventional hose.

According to one embodiment or objective of the present invention, ahose assembly is disclosed comprising a lightweight elastomeric orthermoplastic inner tube surrounded by a fabric-like or non-fabric outertube that serves as a jacket for the inner tube. This jacket alsoprevents the length of the product from changing at different pressureconditions. The length of the product is fixed by the length of theouter jacket. The inner tube can expand longitudinally along thelength-wise axis of the hose between hose ends or couplers, as well asalong a radial axis of the tube when pressure at or above a minimumfluid pressure is applied to the inner tube. When the pressure fallsbelow the minimum fluid pressure, the inner tube of the hose assemblywill contract both longitudinally and radially. The longitudinal andradial rates of contraction depend on the composition of the inner tube.The outer tube limits the longitudinal and radial expansion of the innertube in one embodiment.

Still another embodiment or objective of the present invention is toprovide a hose assembly including a fabric outer tube or non-fabricouter tube that is welded around the inner tube and includes a weld seamextending along a longitudinal axis of the hose assembly. The weld seamhas a greater thickness, i.e. wall thickness, as compared to a wallthickness of the unwelded fabric.

Yet another embodiment or objective of the present invention is toprovide a method for producing a hose assembly comprising a hot airwelding or seaming process whereby the outer tube is formed via welding,preferably hot air welding, around the inner tube, preferably utilizinga continuous process. It is possible for the circumferential size of theouter tube to be varied in order to produce hose assemblies havingdifferent maximum internal diameters of the inner tube.

An additional embodiment or objective of the present invention is toprovide a method for producing a hose assembly comprising the steps ofobtaining a polymeric or synthetic fabric or non-fabric material or acombination thereof, heating lateral sides of the material at or above amelting temperature thereof and bonding the lateral sides togetheraround an inner tube in order to form a weld. As the fabric ornon-fabric material or a combination thereof is bonded along the lengthof the inner tube, the outer tube is formed having a weld seam along thelongitudinal length of the hose assembly. Advantageously, the processfor preparing the hose assembly of the present invention allowsmanufacture of an outer tube having a weld that is stronger than theoriginal material has relatively low labor costs and also produces aconstruction having the inner tube inserted into the outer tube as partof the welding process.

An additional embodiment or objective of the present invention is toprovide a hose assembly capable of resisting water pressures in the 400psi range (pounds per square inch) 2758 kPa. Even though the hose is ofa robust construction, the assembly is relatively light in weight, forexample about 4 lbs per 50 feet (0.12 kg per meter) in one preferredembodiment.

In one aspect, a hose assembly is disclosed, comprising an inner tubecomprising an elastomeric material, wherein the inner tube has alongitudinal length and a first circumference below a minimum expansionpressure, wherein the inner tube and is expandable to longer, secondlongitudinal length and a larger, second circumference upon applicationof fluid pressure on an inner surface of the inner tube at or above theminimum expansion pressure; and an outer tube covering the inner tube,the outer tube having a longitudinal length and a weld seam along thelongitudinal length of the outer tube, the weld seam comprising meltedouter tube material.

In another aspect a process for producing a hose assembly is disclosed,comprising the steps of obtaining an inner tube comprising anelastomeric material, wherein the inner tube has a first longitudinallength and a first circumference below a minimum expansion pressure,wherein the inner tube and is expandable to longer, second longitudinallength and a larger, second circumference upon application of fluidpressure on an inner surface of the inner tube at or above the minimumexpansion pressure; obtaining a material having a first end, a secondend a first side and a second side, the sides located between the ends;wrapping the material around the inner tube and abutting the first sideand the second side of the material, and heating the material to meltand bond the first side to the second side along a length of the sidethereby forming an outer tube having a weld seam along a longitudinallength of the hose assembly, wherein during formation of the outer tubea section of the inner tube is located inside the outer tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and other features andadvantages will become apparent by reading the detailed description ofthe invention, taken together with the drawings, wherein:

FIG. 1 is a partial, cross-sectional, longitudinal side view of oneembodiment of a hose assembly of the present invention in alongitudinally and circumferentially contracted position;

FIG. 2 is a partial, cross-sectional, longitudinal side view of oneembodiment of a hose assembly of the present invention in an expandedposition; and

FIG. 3 is a partial, longitudinal side view of one embodiment of thehose assembly of the present invention particularly illustrating a weldseam of the outer tube produced by a hot air seaming method that encasesan inner tube within the outer tube.

DETAILED DESCRIPTION OF THE INVENTION

In this specification, all numbers disclosed herein designate a setvalue, individually, in one embodiment, regardless of whether the word“about” or “approximate” or the like is used in connection therewith. Inaddition, when the term such as “about” or “approximate” is used inconjunction with a value, the numerical range may also vary, for exampleby 1%, 2%, 5%, or more in various other, independent, embodiments.

The hose assembly of the present invention includes a fabric and/ornon-fabric jacketed inner tube, with the hose assembly being relativelylight in weight, durable and versatile. The inner tube can expandcircumferentially or radially to an expanded position or state inresponse to at least a minimum fluid pressure applied internally to theinner tube. In additional embodiments, the inner tube can expandlongitudinally along the length-wise axis of the tube in response to atleast minimum fluid pressure applied internally to the inner tube. Thecircumference of the jacket controls radial expansion of the inner tube.The length of the jacket controls longitudinal expansion of the innertube. The inner tube circumferentially or radially and longitudinallycontracts when fluid pressure inside the tube falls below the minimumfluid pressure to a contracted or non-expanded position or state.Elastomer-containing inner tubes generally contract at faster rates thaninner tubes formed from compositions comprising thermoplastic polymers,such as polyvinyl chloride. In one embodiment, the outer tube jacket isformed around the inner tube in a continuous process that welds a fabricand/or non-fabric material, preferably using hot air, into the jacket.

Referring now to the drawings wherein like reference numbers refer tolike parts throughout the several views, a hose assembly 10 isillustrated in FIGS. 1 and 2, wherein FIG. 1 illustrates the hoseassembly in an out-of-service or contracted position and FIG. 2 anexpanded position. Hose assembly 10 includes an inlet 14 and an outlet16, with fluid passage 12 being located therebetween. The hose assemblyincludes an inner tube 20 that extends between and fitting or couplers,see for example male coupler 60 and female coupler 50. The inner tube 20is self-expanding and self-contracting. Inner tube 20 has an innersurface 22 and an outer surface 24, see FIGS. 1-2, for example. When afluid, such as water when the hose assembly is utilized as a gardenhose, is introduced into the inner tube 20 and exerts at least a minimumfluid pressure on an inner surface 22, the inner tube 20 expands,generally radially, from a first circumference to a larger, secondcircumference in an expanded position; and longitudinally between thecouplers 50, 60. In some embodiments the inner tube 20 is formed from amaterial that can expand longitudinally to a length that is generally atleast two times, desirably between 2 and 4 times and preferably at leastfour times the length of the inner tube 20 when in a relaxed orcontracted position. Inner tube 20 can be formed such that the secondcircumference provides the tube inner surface 22 with a desired innerdiameter, for example about 0.5 inch (1.27 cm) or about 0.625 inch (1.59cm). When fluid pressure decreases below the minimum fluid pressure, theinner tube 20 relaxes or contracts radially, preferably back to thefirst circumference in one embodiment. In other embodiments, the innertube may not contract to the first circumference.

The thickness of the inner tube 20 can vary depending upon the materialsutilized to construct the same. In various embodiments, the wallthickness of the inner tube ranges generally from about 1.0 to about 2.0mm, desirably from about 1.2 to about 1.8 mm, preferably from about 1.40to about 1.65 mm, as measured in a radial direction in a contractedposition.

Hose assembly 10 also includes a jacket, sheath or outer tube 40 that isalso connected between first and second couplers, see for example malecouplers 60 and female couplers 50. In one embodiment, the outer tube 40is not connected or attached to the inner tube 20 or an outer slipcoating layer 30, further described below, between the couplers. Statedin another manner, the outer tube 40 is preferably unattached,unconnected, unbonded, and unsecured to either the inner tube 20 or slipcoating layer 30, when present, along the entire length of the innertube 20 and slip coating layer 30 between the first end and the secondend of the outer tuber 40, and thus the tube 40 is able to move freelywith respect to the inner tube 20 and/or slip coating layer 30 when thehose assembly expands or contracts. In one embodiment, the longitudinaland circumferential or radial expansion of inner tube 20 is limited bythe dimensions, i.e. maximum length and/or inner diameter orcircumference of outer tube 40. The outer tube 40 is configured toprotect the inner tube 20 and slip coating layer 30, when present, suchas from cuts, friction, abrasion, puncture, over-expansion (bursting) orUV exposure.

In various embodiments the outer tube 40 can be braided or woven into afabric that is subsequently formed into the tube. Non-woven fabrics areutilized in some embodiments. In additional embodiments, the outer tubeis formed from a non-fabric material, such as a film, fiber-reinforcedfilm, sheet or similar construction. Suitable materials include, but arenot limited to, polyolefins, polyesters, and polyamides such as nylon.Natural materials can be used in some embodiments. Polyester ispreferred in some embodiments. Outer tube 40 should be formed from amaterial that is pliable and strong enough to withstand a desiredinternal pressure that can be exerted by outer surface 24 of inner tube20. Thickness of the outer tube 40 is dependent on yarn denier whenfabric-like materials are used. This will be dictated by desiredinternal pressure as mentioned above.

In an important aspect of the present invention, the hose assemblyjacket or outer tube 40 is formed around the inner tube 20, preferablyin a continuous process. In a preferred embodiment a hot air weldingprocess is utilized. While the process described utilizes the term“fabric”, it is to be understood that the process is applicable to eachof, and is thus inclusive of, the materials described herein. During theprocess, a piece of fabric (or other material) having first and secondends and first and second sides located therebetween is formed into atubular shape. A portion of the first side and the second side is heatedto a temperature where the material, in particular polymer, that formsthe fabric melts and the sides are bonded together, with the inner tubebeing present within or surrounded by the outer tube formed by thefabric. A weld 46 is formed in the area where the fabric is heated andthe sides are joined. As the fabric is joined along the length of thesides, the welded fabric forms a spine or weld seam 48 extendinglongitudinally along the length of the fabric, comprising melted fabric.In a preferred embodiment, the weld seam has an overlap or weld width of0.375 inch (9.5 mm)+/−0.0625 inch (+/−1.5 mm), generally measuredperpendicular to the longitudinal length of the weld seam. In anotherembodiment, the variation is +/−3 mm. In one embodiment, the processthat forms the welded seam is a continuous process that heats the fabricwith hot air, with temperatures ranging between 550 and 750° C. andpreferably between 600 and 700° C. The welding process also produces aweld seam having a wall thickness that is generally at least 50%greater, desirably at least 75% greater and preferably about 100%greater, i.e. two times greater, than the average thickness of thenon-welded fabric of the outer tube.

In one embodiment, the inner tube 20 is supplied from a reel or spool.In another embodiment, the inner tube 20 is supplied directly from anupstream extrusion line. The inner tube enters a folding fixture whichcontains a series of guides and is combined with a flat, woven fabric.The fabric is supplied from a fabric source, such as a bulk containerand straightened and tensioned as it enters the folding fixture. Thefolding fixture partially forms the fabric around the inner tube. Theinner tube and fabric then enter a die which completes the formingprocess by shaping the fabric into a round, tubular shape. The tubularfabric profile and inner tube exit the die. At the exit of the die, anozzle directs hot air between the overlapped fabric side surfaces. Thishot air heats the fabric to or above its melting point just before thefabric and inner tube pass through a set of nip rollers which force theheated fabric surfaces against each other under pressure. A strong bondbetween the two fabric surfaces is formed at this point. The fabric andtube may be wound onto a reel for future assembly or cut to length andprocessed into a finished hose immediately. Hot air seaming devices areavailable from companies such as Miller Weldmaster of Navarre, Ohio.

Inner tube 20 can be formed from any suitable elastic or polymericmaterial. Elastomeric materials are preferably utilized when inner tube20 is longitudinally expandable. Suitable materials include, but are notlimited to, rubbers including natural rubber, synthetic rubber andcombinations thereof; thermoplastics; and various thermoplasticelastomers including thermoplastic vulcanizates. Suitable thermoplasticelastomers include but are not limited to styrenic block copolymers, forexample SEBS, SEEPS, and SBS; and SIS. In one embodiment the elastomericinner tube has a hardness that ranges from 20 to 60 Shore A, desirablyfrom 25 to 60 Shore A, and preferably from 30 to 50 Shore A, as measuredaccording to ASTM D-2240. Suitable thermoplastics include but are notlimited to polyvinyl chloride (PVC). Non-limiting examples of suitablegrades of PVC include standard and high molecular weight.Thermoplastic-containing inner tubes have a hardness that ranges from 50to 80 Shore A, and preferably from 60 to 70 Shore A, as measuredaccording to ASTM D-2240. In various embodiments, the inner orexpandable tubes or any constructions described in one or more of thefollowing patents and publications can be utilized and are herewithincorporated by reference: U.S. Pat. Nos. 6,948,527; 7,549,448;8,371,143; 8,776,836; 8,291,942; 8,479,776; 8,757,213; 8,936,046;9,022,076; as well as U.S. Patent Application Publication Nos.2014/0150889; 2014/0345734; 2015/0007902; 2015/0041016; 2015/0129042 andInternational Publication Nos. WO2014/169057; and WO2015/023592.

The inner tube compositions of the present invention may includeadditional additives including, but not limited to antioxidants, foamagent, pigments, heat stabilizers, UV absorber/stabilizer, processingaids, flow enhancing agents, nanoparticles, platelet fillers andnon-platelet fillers.

In some embodiments of the present invention, slip coating layer 30 isprovided on outer surface 24 of inner tube 20, see FIGS. 1 and 2. In apreferred embodiment, the slip coating layer 30 can be extruded onto orcoextruded with the inner tube 20 layer. Other application methods suchas coating would also be acceptable so long as the slip coating performsits intended function. In some embodiments of the present invention, aslip coat may not be necessary depending on the inner tube materialsselected and the manufacturing method.

The slip coating layer 30 can be a continuous or discontinuous layer orlayers. In one preferred embodiment the slip coating layer iscontinuous, at least prior to a first expansion of inner tube 20 afterthe slip coating layer has been applied. Depending on the thickness ofthe slip coating layer 30 relatively thin layers, after one or moreexpansions of the inner tube 20, may exhibit cracking, splitting,crazing, fracturing or the like. Importantly though, such layers havestill been found to be effective. That said, the initial thickness ofthe slip coating layer 30 ranges generally from about 0.025 mm to about0.51 mm, desirably from about 0.05 to about 0.25 and preferably fromabout 0.10 to about 0.20 mm, or about 0.15 mm measured in a radialdirection.

As illustrated in FIGS. 1 and 2, the slip coating layer 30 is locatedbetween the inner tube 20 and the outer tube covering 40. In a preferredembodiment, the slip coating layer is not directly connected to theouter tube covering 40 between the first coupler and the second coupler,e.g. male coupler 60 and female coupler 50, such that the outer tubecovering 40 can slide or otherwise move in relation to the slip coatinglayer 30 during expansion and contraction of hose assembly 10. In anexpanded position, the outer surface of the slip coating layer 30 is incontact with the inner surface of the outer tube covering 40.

The slip coating layer comprises a lubricant, optionally incorporatedinto or blended with a carrier material.

In one embodiment, the lubricant is a siloxane polymer or copolymer, ora fluorinated polymer or a combination thereof. A siloxane polymermasterbatch is available from Dow-Corning as MB50-321™ and from Wackeras Genioplast™. Fluorinated polymer is available from McLube as MAC1080™ In some embodiments lubricant is present in the slip coating layerin an amount generally from about 1 to about 40 parts, desirably fromabout 2 to about 30 parts and preferably in an amount from about 3 toabout 20 parts based on 100 total parts by weight of the slip coatinglayer. In other embodiments, the lubricant can be a liquid, semi-solidor solid material that serves to reduce friction between the inner tubeand the outer tube. Non-limiting examples of other lubricants include,but are not limited to, oils such as silicone oil, waxes, polymers,including elastomers.

As described herein, in one embodiment the lubricant is mixed with acarrier material that aids in affixing the lubricant on an outer surfaceof the inner tube. Suitable materials include, but are not limited to,polyolefins, thermoplastic elastomers or a combination thereof. In oneembodiment, the carrier material comprises a polyolefin and one or moreof the thermoplastic elastomers utilized in the inner tube layer.

Along with the lubricant, the slip coating layer may also includeadditional additives including, but not limited to, antioxidants,foaming agents, pigments, heat stabilizers, UV absorber/stabilizer,processing aids, flow enhancing agents, nanoparticles, platelet fillersand non-platelet fillers. Various other lubricants or slip coatinglayers known to those of ordinary skill in the art may also be utilized,if desired.

Hose assembly 10 includes male coupler 60 at a first end and femalecoupler 50 at a second end. The male coupler 60 includes an externalthreaded section 62 and an internal connector 63 fixedly connected, suchas by a press fit, to main body 66 of male coupler 60. Connector 63includes a stem 64 initially having a smaller diameter portion 63 thatis connected to a larger diameter portion connected to the inner side ofthreaded section 62. Fluid passing through male coupler 60 passesthrough internal connector 63, generally through aperture 67 in stem 64and out through the end of connector 63 within threaded section 62. Inone embodiment, the stem 64 is inserted into the inner tube 20. Aportion of the outer tube covering 40 is also located between stem 64,inner tube 20 and the ferrule 68 of male coupler 60. Inner tube 20 andouter tube 40 are operatively connected and secured to male coupler 60by expansion of the stem 64 outwardly towards ferrule 68. In otherembodiments the ferrule can be crimped towards a relatively rigid stemin order to capture the inner tube and outer tube therebetween, securingthe tubes to the male coupler 60. Other attachment mechanisms could alsobe utilized.

The female coupler 50 includes a main body 56 having an internalthreaded section 52 that is operatively and rotatably connected to asecond end of hose assembly 10 opposite the end containing male coupler60. Threaded section 52 is constructed such that it can be operativelyconnected to a male fitting of a spigot, faucet, or other similar valvecontrol device.

The internal connector 53 of female coupler 50 is rotatable in relationto main body 56 such that the main body is also rotatable in relation tothe inner tube 20 and outer tube 40 which are operatively connected orfixed to stem 54. A ferrule 51 is placed onto the jacket or outer tube40 and inner tube 20. The ferrule 51, inner tube 20, and fabric jacketouter tube 40 are then fitted onto stem 63. Stem 63 is then expanded tosecure the hose to the fitting. As mentioned above with respect to themale coupler, alternative constructions can be utilized to secure theinner tube 20 and outer tube 40 to the female coupler 50. As illustratedin FIG. 1, connector 53 includes a receptacle 55 in the form of acavity, recess, or the like that accommodates flange 57 of the main body56. In the embodiment illustrated, the flange 57 is a ring-like featureprojecting inwardly from the main body 56 and includes an end that islocated within receptacle 55. The flange structure allows the main body56 to spin or rotate around connector 53. A washer 59 is located at thebase of threaded section 52 in order to provide a desired seal betweenthe female coupler and a device that is threadably connectable tothreaded section 52.

Alternatively, other common couplers, fittings or hose end connectionscan be utilized and include, but are not limited, crimped (external),barbed, or clamped couplings made from plastics, metals, or combinationsthereof.

The hose assembly 10 is illustrated in a contracted position withrespect to length and circumference in FIG. 1. In this position, theelastic inner tube 20 is in a contracted or relaxed state with nointernal force being applied to the inner surface 22 sufficient toexpand or stretch inner tube 20. Depending on the material utilized forouter tube covering 40, space may exist between the same and the slipcoating layer 30, if present, and/or inner tube 20 when the hoseassembly is in a contracted position.

The fluid pressure within inner tube 20 can be increased for example bypreventing fluid from being expelled through outlet 16, such as with theuse of an associated nozzle or the like (not shown) and introducingfluid under pressure into the inlet 14 of hose assembly 10. Once aminimum threshold pressure is met or exceeded, the inner tube 20undergoes longitudinal and/or circumferential expansion. Expansion ofinner tube 20 results in a decrease in wall thickness of the inner tubeand an increase in the circumference or diameter of the inner tubeand/or the length of the inner tube in some embodiments. Thus, a highervolume of fluid can be present in inner tube 20 in the expanded positionas compared to the volume of fluid that can be present in a contractedposition, below the minimum fluid pressure.

Depending upon the construction of the outer tube covering 40, in theexpanded position, the covering may exhibit a relatively smooth,cylindrical character along its length, see FIG. 2 for example.

Standard water pressure for water exiting a spigot from a municipalwater system is about 45 to about 75 psi (310.3 to 517.1 kPa) andtypically about 60 psi, 413.7 kPa. Such pressure is sufficiently above aminimum fluid pressure required for the hose to expand. The minimumfluid pressure that causes the inner tube 20 of hose assembly 10 toexpand will vary depending on the construction or composition thereof.When a nozzle or other flow restricting device is connected to the malecoupler 60 of hose assembly 10, with the female coupler 70 beingoperatively connected to a spigot, the inner tube 20 will expand whenthe spigot valve is opened or turned on as water under pressure willflow into the hose. If the nozzle prevents the flow of fluid through theinner tube, the pressure inside the inner tube will achievesubstantially the same pressure as that coming from the fluid pressuresource, such as 60 psi (289.6 kPa) in the case of a standard municipalwater supply. When fluid is released from the outlet 16 of hose assembly10 through a suitable nozzle, the pressure inside the inner tube 20 isreduced. The hose assembly will remain in an expanded position when thefluid pressure remains above the minimum fluid pressure. In a preferredembodiment, the couplers are full flow fittings. They are not designedto create back pressure within the hose.

The hose assemblies formed by the present invention are relativelylightweight, when compared to a conventional garden hose. Hoseassemblies of the present invention are capable of withstanding waterpressures in the 400 psi (2758 kPa) range while still being relativelylight. For example, a 50 foot hose assembly of the present inventionincluding couplers or end fittings can weigh about 4 or 5 lbs. withinner and outer tubes that are about 50 feet in length. The hoseassemblies are very flexible and can be easily stored in compact spacesthat a conventional garden hose would not fit, such as a bucket orsimilar container. The hot air seaming or welding process according tothe present invention allows manufacture of a hose assembly utilizingless labor input, while having the inner tube automatically insertedinto the outer tube which is formed therearound as part of the weldingprocess.

The hose assemblies of the present invention are particularly suitablefor cold water applications.

Due to the flexibility and versatility of the hose assemblies, one canutilize a fastener system such as a hook and loop fastener system, forexample VELCRO® to harness the hose assembly when not in use. A fastenerstrap can be attached to one end of the hose by threading an end of afastener through a female eyelet thereof such that the fastener can bepermanently affixed to the hose assembly.

The hose assemblies of the present invention can also be formed from FDAlisted ingredients for non-food contact applications, such as RV andmarine drinking water service.

EXAMPLES

Burst Testing

One embodiment of a garden hose assembly according to the presentinvention including a fabric outer tube having a weld seam formed from ahot air welding process, the weld seam extending along a longitudinallength of the outer tube, the weld seam comprising melted fabric, waspressurized to failure. The peak pressure was recorded. This product wascomparable to heavy duty, conventional constructions.

Elevated Temperature Burst

Garden hose assemblies as described in the example above were bursttested at 120° F. to determine how they would perform in hot conditions.This inventive construction did not lose as much burst strength at hightemperatures compared to existing constructions.

Puncture Resistance

A pointed penetrator was forced against a pressurized hose assembly asdescribed above. The peak force required to form a leak was recorded.This construction was comparable to heavy duty, conventionalconstructions.

While in accordance with the patent statutes the best mode and preferredembodiment have been set forth, the scope of the invention is notlimited thereto, but rather by the scope of the attached claims.

What is claimed is:
 1. A hose assembly, comprising: an inner tubecomprising an elastomeric material, wherein the inner tube has a firstlongitudinal length and a first circumference below a minimum expansionpressure, wherein the inner tube is expandable to longer, secondlongitudinal length and a larger, second circumference upon applicationof fluid pressure on an inner surface of the inner tube at or above theminimum expansion pressure; and an outer tube covering the inner tube,the outer tube having a longitudinal length and a weld seam along thelongitudinal length of the outer tube, the weld seam comprising meltedouter tube material, wherein the hose assembly further includes a malecoupler connected to first ends of the inner tube and the outer tube anda female coupler connected to second ends of the inner tube and theouter tube, and wherein the outer tube is not connected or attached tothe inner tube between the male coupler and the female coupler.
 2. Thehose assembly according to claim 1, wherein the outer tube has a firstend and a second end and two sides between ends, wherein the two sidesare bonded at the weld seam, and wherein the second longitudinal lengthis at least two times greater than the first longitudinal length.
 3. Thehose assembly according to claim 1, wherein the outer tube has an innersurface with a circumference and the second circumference of the innertube is less than or equal to the outer tube inner surfacecircumference.
 4. The hose assembly according to claim 1, wherein thehose assembly further includes a slip coating layer directly contactingthe inner tube.
 5. The hose assembly according to claim 1, wherein theweld seam has a weld width of 9.5 mm+/−3.0 mm, and wherein the weld seamhas a weld thickness that is at least 50% greater than a thickness ofthe fabric of the outer tube in a non-weld seam section.
 6. The hoseassembly according to claim 5, wherein the weld seam weld width is 9.5mm+/−1.50 mm, and wherein the weld thickness is at least 75% greaterthan the thickness of the material of the outer tube in the non-weldseam section.
 7. The hose assembly according to claim 6, wherein theweld seam weld thickness is at least 100% greater than the thickness ofthe material of the outer tube in the non-weld seam section.
 8. Aprocess for producing the hose assembly according to claim 1,comprising: obtaining the inner tube comprising the elastomericmaterial; obtaining a material having a first end, a second end, a firstside and a second side, the sides located between the ends; wrapping thematerial around the inner tube and abutting the first side and thesecond side of the material, and heating the material to melt and bondthe first side to the second side along a length of the sides therebyforming the outer tube having the weld seam along a longitudinal lengthof the hose assembly, wherein during formation of the outer tube asection of the inner tube is located inside the outer tube.
 9. Theprocess according to claim 8, further including the step of overlappingthe first side and the second side of the fabric 9.5 mm+/−3.0 mm. 10.The process according to claim 9, further including the step ofoverlapping the first side and the second side of the fabric 9.5mm+/−1.5 mm.
 11. The process according to claim 9, wherein the heatingstep comprises heating the material with hot air at a temperaturebetween 550° C. and 750° C.
 12. The process according to claim 11,further including the step of partially forming the material around theinner tube with a folding fixture and shaping the material into a round,tubular profile using a die.
 13. The process according to claim 12,further including a step of passing the inner tube and outer tubethrough a set of rollers which force the heated material surfacesagainst each other under pressure after the heating step.
 14. Theprocess according to claim 8, wherein the heating step comprises heatingthe material with hot air at a temperature between 550° C. and 750° C.15. The process according to claim 14, further including the step ofpartially forming the material around the inner tube with a foldingfixture and shaping the material into a round, tubular profile using adie.
 16. The process according to claim 15, further including a step ofpassing the inner tube and outer tube through a set of rollers whichforce the heated material surfaces against each other under pressureafter the heating step.
 17. The process according to claim 8, whereinthe second longitudinal length is at least two times greater than thefirst longitudinal length.